 | 2015 |
Abstract:
Modern lightweight design concepts, like the space frame design and multi-material structures, have complex demands on joining technologies, and conventional processes are often pushed to their technological limits. An interesting alternative for connecting extruded aluminum profiles without heating or penetration is joining by electromagnetic crimping. Compared to adhesive bonding and welding, the process also requires a less extensive joining zone preparation. However, existing process design methodologies require either extensive experimental studies or sophisticated numerical modeling. Therefore, an analytical approach for the determination of process parameters, like the applied charging energy, is presented in this article. Besides groove geometry and workpiece properties, the model also considers the electrical characteristics of the electromagnetic forming equipment. Experimental studies of the joining process are performed to verify the developed model. Additionally, the electromagnetic crimping operation is numerically modeled for a more detailed analysis of this process.